Unitary dispenser assembly with break-away cap

ABSTRACT

A dispenser assembly having a dispenser made from a first polymeric material which has a first melting point. The dispenser also having an attachment portion and a dispensing portion. The dispenser assembly further including a cap formed as single unitary component with the dispenser and made from a second polymeric material having a second melting point which is lower than the first melting point.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a non-provisional of, and claims the benefit and priority of, U.S. Provisional Patent Application No. 62/264,398, filed on Dec. 8, 2015. The entire contents of such application are hereby incorporated by reference.

BACKGROUND

Dispenser assemblies are used to dispense a variety of substances from containers or receptacles in a very controlled and accurate fashion. These dispenser assemblies can be attached to a receptacle to allow users to carefully control the amount of substance dispensed from the receptacle as well as where the substance is dispensed to. Dispenser assemblies may also help to seal the contents of the receptacle from contamination and spillage. Unfortunately, the dispenser assemblies on the market today have several drawbacks including their tendency to be damaged during shipping, which causes contamination and/or spilling of receptacle contents and overall product loss. Current dispenser assemblies also suffer from high manufacturing costs due to the use of complex molding processes, post molding alterations such as additional cutting to create zones of weakness or frangible bridges, and/or having to separately mold several components and assemble them together. These are just some of the properties that make the current dispenser assemblies on the market less than ideal.

SUMMARY

The subject matter disclosed herein relates to a dispenser assembly with a break-away cap that may be attached to a receptacle. Specifically, the present disclosure describes a dispenser assembly that is molded using a two-step molding process that forms the dispenser portion and the cap portion as a single unitary component or piece. A receptacle may be attached to the dispenser assembly to allow for controlled dispensing of the contents of the receptacle.

In an embodiment, the dispenser assembly comprises a dispenser formed from a first polymeric material having a first melting point. The dispenser comprises an attachment portion including a top end and a radial shoulder defining an orifice. The dispenser further includes a dispensing portion extending from the top end and having an interior surface which defines a channel that extends from the orifice to a nozzle. The dispenser assembly further comprises a cap formed from a second polymeric material having a second melting point which is lower than the first melting point. The cap comprises a bottom end with a bottom diameter configured to cover at least a portion of the nozzle, wherein the dispenser portion and the cap are formed as a single unitary component or piece, and wherein the cap may be broken away from the at least portion of the nozzle.

In another embodiment, a nozzle assembly comprises a nozzle formed from a first polymeric material having a first melting point. The nozzle includes an attachment portion including a top end and a radial shoulder defining an orifice. A nozzle portion extends from the top end and has an interior surface which defines a channel. The channel extends from the orifice to an ejection area. The nozzle assembly further comprises a cap formed from a second polymeric material having a second melting point which is lower than the first melting point. The cap is configured to cover at least a portion of the ejection area and seal an end of the channel. The nozzle and the cap are formed as a single unitary component or piece.

Some advantages that may be realized in the practice of some disclosed embodiments of the dispenser assembly are greater durability during shipping and more efficient and cheaper manufacturing of the dispenser assembly.

This brief description of the invention is intended only to provide a brief overview of subject matter disclosed herein according to one or more illustrative embodiments, and does not serve as a guide to define or limit the scope of the invention. This brief description is provided to introduce an illustrative selection of concepts in a simplified form that are further described below in the detailed description. This brief description is not intended to identify key features or essential features of the invention, nor is it intended to be used as an aid in determining the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the features of the invention can be understood, a detailed description of the invention may be had by reference to certain embodiments, some of which are illustrated in the accompanying drawings. It is to be noted, however, that the drawings illustrate only certain embodiments of this invention and are therefore not to be considered limiting of its scope, for the scope of the invention encompasses other equally effective embodiments. The drawings are not necessarily to scale, emphasis generally being placed upon illustrating the features of certain embodiments of the invention. In the drawings, like numerals are used to indicate like parts throughout the various views. Thus, for further understanding of the invention, reference can be made to the following detailed description, read in connection with the drawings in which:

FIG. 1 is a side view of an embodiment of the dispenser assembly attached to a receptacle or vessel;

FIG. 2 is a side view of an embodiment of a receptacle;

FIG. 3 is a perspective view of an embodiment of the dispenser attached to a receptacle;

FIG. 4 is a perspective view of another embodiment of the dispenser attached to a receptacle;

FIG. 5 is a perspective view of an embodiment of the dispenser;

FIG. 6 is a cross sectional view of an embodiment of the dispenser;

FIG. 7 is a cross sectional view of another embodiment of the dispenser;

FIG. 8 is a partial cross sectional view of an embodiment of the dispenser;

FIG. 9 is a partial cross sectional view of another embodiment of the dispenser;

FIG. 10 is a side view and a top view of an embodiment of the cap;

FIG. 11 is a perspective view of an embodiment of the dispenser and an embodiment of the cap; and

FIG. 12 is a cross sectional view of an embodiment of the dispenser assembly shortly before the cap is broken away by a user.

DETAILED DESCRIPTION

Referring to FIGS. 1-2, in an embodiment, the present disclosure describes a dispenser assembly 100 for a vessel or receptacle 10 using a two-step molding process that forms the dispenser assembly as a single unitary component or piece. The receptacle 10 is attached to the dispenser assembly 100 at an opening 14 of the receptacle 10. As shown, the dispenser assembly 100 includes a nozzle or dispenser 200 and a cap 300. The dispenser 200 may be attached at one end to the open end 4 of the receptacle 10 and the cap 300 is formed at the opposite end of the dispenser 200. The cap 300 acts to seal off the contents of the receptacle 10 when the dispenser assembly 100 is attached to the opening 14. The cap 300 may help protect the contents of the receptacle 10 from environmental contaminants as well as prevent the contents of the receptacle 10 from spilling during shipping. The cap 300 and the dispenser 200 are manufactured such that in the assembled position, they comprise a single unitary component or piece. This method of manufacture makes the dispenser assembly 100 easier and cheaper to manufacture, as well as less prone to breakage or damage during shipping while still allowing the user to easily break the cap 300 away from the dispenser 200 in order to begin dispensing the contents of the receptacle 10.

In the embodiments illustrated in FIGS. 1-2, the receptacle 10 is substantially tubular in shape and has a top 12 and a bottom 13. It should be appreciated that other embodiments of the receptacle may exist that are not substantially tubular in shape. Referring to FIG. 2, the top 12 includes an opening 14 with a first diameter D1, which provides access to an interior space 20. The interior space 20 may be occupied by a variety of liquids, semi-liquids, powders, small particles, or any other product or substance suitable for dispensing from the dispenser assembly 100. The first diameter D1 may be large enough to allow for direct filling of the interior space 20, or it may be of a size such that filling the interior space 20 is best accomplished with the aid of a funnel or other device. Still referring to FIG. 2, the interior space 20 may comprise a second diameter D2 that is larger than the first diameter D1. In an embodiment, a transition portion 17 is proximate the opening 14 and has sides that are tapered or generally frustoconical in shape in order to direct the contents of the interior space 20 towards the dispenser assembly 100. In an embodiment, the bottom 13 of the receptacle 10 may include a bottom surface 18 with a third diameter D3 that is larger than the first diameter D1, but smaller than the second diameter D2. It can be appreciated that two or more of the diameters D1, D2, D3 may be equal or that the third diameter D3 may be greater than each of the first diameter D1 and the second diameter D2.

Referring still to the embodiment shown in FIG. 2, the opening 14 may include a neck 15 with a threaded exterior 11 and an interior surface 19 (FIGS. 6-7). In other embodiments, the neck may have a threaded interior surface. The neck 15 is configured to engage a portion of the dispenser assembly 100 to form a liquid tight or air tight seal. One of ordinary skill in the art will appreciate that engagement with the dispenser assembly 100 may occur by a means other than threaded engagement that would result in a liquid tight or air tight seal. The receptacle 10 may be made of any suitable inert, flexible polymeric material that would deform to some degree when subjected to axial and/or radial compression, such as soft low-density polyethylene. The receptacle 10 may be formed using a variety of techniques including injection molding or any other suitable fabrication method.

Referring to the embodiments shown in FIGS. 3-4, the dispenser 200 is comprised of an attachment portion 222 and a dispensing portion 224. The attachment portion is located at the bottom 204 of the dispenser 200 and the dispensing portion is located at the top 202 of the dispenser 200. As shown in FIGS. 3-5, the attachment portion 222 is generally tubular in shape with an exterior surface 225, a receiving end 223 (FIG. 5), an attachment surface 226 (FIG. 5) and a top surface 228. Still referring to FIGS. 3-5, the exterior surface 225 of the attachment portion 222 may be smooth or may include ridges, grooves, detents or any surface feature that may aid the user in attaching and detaching the dispenser assembly 100 from the receptacle 10. In the embodiment shown in FIG. 5, the attachment surface 226 includes a threaded area 230 which engages the threaded exterior 11 of the neck 15 of the receptacle 10 (FIG. 2) to create a liquid tight or air tight seal. One skilled in the art can appreciate that the attachment surface 226 may include a means of engaging the receptacle 10 other than threads. As shown in FIGS. 5-7, a radial shoulder 232 protrudes inwardly from the attachment surface 226 and defines an orifice 220 (FIG. 5). An annular lip 234 is adjacent the orifice 220 and extends from the radial shoulder 232 in a direction towards the receiving end 223.

The neck 15 of the receptacle 10 (FIG. 2) is received by the receiving end 223 (FIG. 5) of the dispenser 200 and the threaded exterior 11 of the neck 15 of the receptacle 10 engages the threaded area 230 of the dispenser 200. Rotating the dispenser 200 about the threaded area 230 causes the threads of threaded exterior 11 of the receptacle 10 to engage the complimentary threads of the threaded area 230 of the dispenser 200 in order to create a liquid tight and/or air tight seal. The radial shoulder 232 may contact a surface of the neck 15 and act as a stop to prevent damage to the dispenser assembly caused by over rotation or tightening of the dispenser 200 onto the receptacle 10. In the assembled position shown in the embodiments of FIGS. 6-7, the annular lip 234 rests inside the interior surface 19 of the neck 15 of the receptacle 10, such that the neck 15 is captured between the attachment surface 226 and the outer surface 213 of the annular lip 234.

Referring to the embodiments shown in FIGS. 6-9, the dispensing portion 224 projects from the top surface 228 of the attachment portion 222 terminates at an ejection area 240. As shown, the dispensing portion 224 has an exterior surface 236 that is generally frustoconical and one or more interior surfaces 233, 235, 245 that define a channel 238. It can be appreciated that the dispensing portion 224 may be comprised of one or more stepped segments, each including an exterior surface and a channel. Each of the stepped segments may represent a decrease in the diameter of the exterior surface as well as a decrease in the diameter of the channel. One of ordinary skill in the art can appreciate that the exterior surface 236 may be smooth as shown in FIG. 3, or may include surface features 217 such as those shown in FIG. 4, or any other type of surface feature required for aesthetic, operational, branding or any other purpose.

The channel 238 extends from the orifice 220 (FIG. 5) to the ejection area 240. As shown in FIGS. 6-9, the channel 238 comprises a loading chamber 227 (FIGS. 6-7), a tapered chamber 229 and a dispensing chamber 231. Referring to FIGS. 6-7, the loading chamber 227 is defined by an interior surface 233 of the annular lip 234. Referring to the embodiment shown in FIG. 6, the opposing sides of the interior surface 233 of the loading chamber 227 are convergent such that the diameter of the loading chamber 227 is greater at the end proximate the receiving end 223 than at the end proximate the tapered chamber 229. As shown in FIG. 7, in another embodiment, the opposing sides of the interior surface 233 may be parallel to each other.

The tapered chamber 229 extends from the loading chamber 227 towards the top 202 of the dispenser 200. As shown in FIGS. 6-9, the tapered chamber 229 is defined by an interior surface 235 with opposing sides that are convergent such that the diameter of the tapered chamber 229 is greatest at the end proximate the loading chamber 227. However, it can be appreciated that the opposing sides of the interior surface 235 of the tapered chamber 229 may be parallel and that the diameter of the tapered chamber 229 may be decreased in a step-like fashion using a series of annular protrusions. Referring to the embodiments shown in FIGS. 6-7, the dispensing chamber 231 extends from the tapered chamber 229 towards the top 202 of the dispenser 200. The dispensing chamber 231 is defined by an interior surface 245 (FIGS. 8-9) with opposing sides that are parallel to each other, however one skilled in the art can appreciate that the interior surface 245 of the dispensing chamber 231 may be tapered. The interior surfaces 233, 235, 245 of the channel 238 are smooth as shown, however one of ordinary skill in the art can appreciate that surface features such as ridges, detents, grooves, or any other surface feature that may improve the flow of material through the channel 238 may be incorporated on the interior surfaces 233, 235, 245 of the channel 238.

Still referring to the embodiments of FIGS. 6-9, the ejection area 240 is located at the top 202 of the dispenser 200 and includes exterior sides 241 that are stepped in from the exterior surface 236 of the dispensing portion 224 (FIGS. 6-7) to form an annular rim 243. The exterior sides 241 of the ejection area 240 extend to a dispensing surface 242 which defines a dispensing end 244 of the channel 238 (FIGS. 3-4). In the embodiment shown in FIG. 3 for example, the dispensing surface is biased or tilted and the dispensing end 244 is elliptical, however it should be appreciated that the dispensing end 244 can be any shape suitable for controlled and precise dispensing of the contents of the receptacle 10. The dispenser 200 may be made of any suitable inert, flexible or non-flexible polymeric material that could withstand the pressure of the contents of the receptacle 10 being forced through it, such as polypropylene.

As shown in the embodiment of FIG. 10, the cap 300 includes an ejection area engagement end 350 and a crown or top 352. The ejection area engagement end 350 includes, in one embodiment, a rim contact surface 354 that is configured to rest on the annular rim 243 (FIG. 8-9) of the dispenser 200. Referring to FIGS. 10-11, one or more fins or extensions 356 may be positioned around the circumference of the cap 300. In an embodiment, the fins 356 have an outside edge 360 and extend from the crown 352 towards the ejection area engagement end 350 in order to provide a gripping surface as well as to provide added support. As shown, the maximum diameter D4 created by the fins 356 is less than the first diameter D1 of the receptacle 10. Referring to the embodiment of FIG. 12, the outside edge 360 of the fins 356 may be even with the exterior surface 236 of the dispenser when the cap 300 is in place covering the ejection area 240 (FIGS. 3-9). The cap 300 may be made of any suitable inert, flexible or non-flexible polymeric material that can withstand the physical stresses that are encountered during packaging and shipping, such as polyolefin.

The dispenser 200 and the cap 300 are formed as a single unitary part or component through a two-step injection mold process. During this process, the dispenser 200 is molded first from a polymeric material with a melting point that ranges from about 420° F. to about 460° F., such as polypropylene. A second injection or shot of polymeric material enters the mold and directly contacts the dispensing surface 242 (FIGS. 3-4) of the dispensing end 244 of the dispenser 200 to form the cap 300. The cap 300 is molded from a second polymeric material with a melting point that ranges from about 380° F. to about 420° F., such as polyolefin which allows the dispenser and the cap to be formed in the same mold. Specifically, the second polymeric material may be injected into the mold at a temperature that is below the melting point of the first polymeric material and above the melting point of the second polymeric material. Consequently, the first polymeric material will remain in a solid state upon injection of the second polymeric material into the mold. The resulting dispenser assembly 100 comprises a single, unitary component or piece that is more rigid and better able to withstand the physical abuse that occurs during shipping than current dispenser assemblies.

In addition, the use of two different polymeric materials with different melting points creates a contact bond or interface bond between the dispenser 200 and the cap 300. The contact bond allows for the dispenser assembly 100 to remain as a unitary part until the user is ready to begin dispensing the contents of the receptacle 10. The contact bond described above that is formed between two polymeric materials allows for the user to beak the cap 300 away from the dispenser 200 without the use of fangible bridges, zones of weakness or any other weakened linkage that would add additional manufacturing steps and/or be vulnerable to breakage during shipping. Referring to FIGS. 10-11, the one or more fins 356 may also act to increase the surface areas of the contact bond, thereby increasing its strength. The polymeric materials used to form the dispenser 200 and the cap 300 can be tinted any color that would be suitable for their desired purpose including each being of the same color, each being of a different color, or one or more parts of the dispenser assembly 100 being tinted the same color as the receptacle 10.

Referring to the embodiments shown in FIGS. 10-12, the cap 300 has a fracture surface 358 that is not visible prior to use. The fracture surface 358 is the portion of the cap 300 that is ins contact with the dispenser 200 while in the assembled position. In other words, the fracture surface 358 is where the low-melting point polymeric material contacts the high-melting point polymeric material. It can be appreciated by one skilled in the art that the rim contact surface 354 (FIGS. 10-11) may be located on the fracture surface 358. Once the cap 300 is broken away from the dispenser 200, the fracture surface 358 is defined as those surfaces formerly part of the contact bond with the dispenser 200. In addition, once the cap 300 is broken away from the dispenser 200, it cannot be reused with the dispenser 200 as a means to reseal the contents of the receptacle 10. This feature has the added benefit of alerting the user to a potentially contaminated or tainted product as evidenced by a broken, partially broken or missing cap 300.

To begin dispensing, the user grasps or contacts the cap 300 with one hand and the dispenser 200 or receptacle 10 with the other and applies shear force or rotational force to the cap 300 in order to break the contact bond and release the cap 300 (FIG. 12). The user then applies radial pressure and/or axial pressure to the receptacle 10 to force the contents through the channel 238 and out the dispensing end 244. A person of ordinary skill in the art will appreciate that varying the type of polymeric material used to form the dispenser 200 and the cap 300 will vary the characteristics and strength of the contact bond. Accordingly, the contact bond may be customized for a particular situation by using a specific high melting point polymeric material for the dispenser 200 and a specific low melting point polymeric material for the cap 300.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention may include other examples that occur to those skilled in the art. 

The following is claimed:
 1. A dispenser assembly comprising: a dispenser formed from a first polymeric material having a first melting point, the dispenser comprising an attachment portion including a top end and a radial shoulder defining an orifice, and a dispensing portion extending from the top end and having an interior surface, the interior surface defining a channel that extends from the orifice to a nozzle; and a cap formed from a second polymeric material having a second melting point which is lower than the first melting point, the cap comprising a bottom end with a bottom diameter configured to cover at least a portion of the nozzle, wherein the dispensing portion and the cap are formed as a single unitary component, and wherein the cap is configured to be broken away from the at least a portion of the nozzle.
 2. The dispenser assembly of claim 1, wherein the attachment portion further comprises a threaded surface configured to engage a receptacle.
 3. The dispenser assembly of claim 1, wherein the first melting point is from about 420° F. to about 460° F.
 4. The dispenser assembly of claim 1, wherein the second melting point is from about 380° F. to about 420° F.
 5. The dispenser assembly of claim 1, wherein the dispenser and the cap are held together by a contact bond.
 6. The dispenser assembly of claim 5, wherein the cap further includes a plurality of extensions configured to increase a surface area of the contact bond.
 7. The dispenser assembly of claim 1, wherein the first polymeric material is a different color from the second polymeric material.
 8. A dispenser assembly comprising: a dispenser formed from a first polymeric material having a first melting point, the dispenser comprising an attachment portion configured to engage a receptacle, the attachment portion including a top end and a radial shoulder defining an orifice, and a dispensing portion extending from the top end and having an interior surface which defines a channel, the channel extending from the orifice to an ejection area; and a cap formed from a second polymeric material having a second melting point which is lower than the first melting point, the cap configured to cover at least a portion of the ejection area and seal an end of the channel, wherein the dispensing portion and the cap are formed as a single unitary component with a contact bond, and wherein the cap is configured to be broken away from the at least a portion of the ejection area.
 9. The dispenser assembly of claim 8, wherein the first melting point from about 420° F. to about 460° F.
 10. The dispenser assembly of claim 8, wherein the second melting point is from about 380° F. to about 420° F.
 11. The dispenser assembly of claim 8, wherein the cap further includes a plurality of extensions configured to increase a surface area of the contact bond.
 12. The dispenser assembly of claim 8, wherein the first polymeric material is a different color from the second polymeric material. 